Multi-dimensional energy supply system for a flame cutting machine

energy chain guides drive, control and data cables to the extremely mobile units

Every flame cutting machine from system manufacturer SATO Schneidsysteme is customised and therefore perfectly designed to meet the individual requirements of each customer. The constantly changing challenges place the highest demands on the diversity and quality of the systems. This also has an impact on individual components such as the various energy supply systems, which are responsible for a smooth cutting process even under the most adverse environmental conditions. Movable multi-axis energy chains from igus® ensure endlessly swivelling axes of the plasma bevel units in all directions.

Profile

What was needed: energy chain of series E4.42, series 3400 and triflex® R, chainflex®-cable, linear guide of series drylin® W
Requirements: Use of the energy supply system under harsh operating conditions such as heat, flying sparks and extreme levels of dirt, use in a compact design, cable feed of extremely mobile units required
Industry: Machine tool construction
Success for the customer: suitable energy supply systems optimally fulfil the various requirements within the system: E4.42 series for high speeds and accelerations, triflex® R series for extreme mobility in all directions; close cooperation in the run-up to the project to ensure the best possible solution. Highly customised customer solution

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Problem

The company SATO Schneidsysteme Anton Hubert e. K. in Mönchengladbach has been a successful manufacturer of CNC-controlled cutting machines in portal and cantilever design for 25 years. The "Satronik" series covers oxyfuel, plasma, laser and waterjet cutting.
The company's flame cutting machines cut sheet metal from a few millimetres up to two metres. To ensure that they function perfectly over the long term in tough everyday operation, which is characterised by heat, flying sparks and extreme levels of dirt, the individual components must be extremely robust and, like the system itself, state-of-the-art.
This also applies to the innovative 3D plasma bevelling unit, which has proven itself many times over in customer use for around two years. With this system component, SATO Schneidsysteme is setting new standards in dynamics, precision and energy efficiency.
The programmable 3D plasma bevel cutting unit is used for processing in the preparation of weld seams in structural and stainless steels. "We have designed it to be particularly compact," explains conductor Reiner Schiffer. "As a unique selling point, the new design ensures an extremely small footprint on the machine as well as high dynamics in the actual cutting process."
The cost-effectiveness of the system can be seen, for example, in the area of multiple panel processing, which can be cut in one go without a break. Another advantage is the minimised waste. The low weight of the unit makes it suitable for use with compact machine types. The 3D plasma bevel cutting units with height sensing, which can be swivelled endlessly without rotation limitation, are in daily use as single and multi-torch versions and cut bevel and trim cuts up to 45°. With a stroke speed of 6,000 or 12,000 mm/min, it can be used for bevel cutting on all plasma systems.

Solution

The energy supply of a cutting system with two 3D plasma bevel units is ensured by energy supply systems from igus®. The E4.42 series, which can be opened on both sides, proves its efficiency on the x-axis with a travel of the entire torch system of 42 metres. It is suitable for high speeds and accelerations as well as long travel distances and high additional loads. The main power supply for the entire flame cutting system runs through it.
Installed in three separate guides, three Series 3400 energy supply units are used for each of the transverse movements on the bridge to supply a 3D bevelling unit. This means that six energy supply systems in a total of six guide troughs provide the supply lines to the two torches. They are easy to install and have a long service life.
One energy supply system in a bracket version runs to each of the two bevelling units. It guides the entire system overhead to the torch and ensures that all up and down movements are carried out safely in the long term.
The triflex® R product range, which can move in all directions and is now available in its third generation, has proven itself on the particularly compact 3D plasma bevelling units, the heart of the machine. It has been specially developed for demanding 6-axis robot applications. The unit moves in several axes. The 3D energy supply systems triflex® R, TRC series in closed design, and TRE in easy design for easy cable insertion, have proven themselves for guiding a wide variety of cables. While all drive, control and data cables, including the cooling system, are safely routed in the TRC version, all special cables that are responsible for the initial ignition of the combustion engine or for accident monitoring, for example, run through the TRE version. There are also the signal cables, which can be easily and quickly pressed into the chains from the outside using the "Easy" principle.

Overview E4.1

Overview E2/000

"We have been working with the energy chain supplier for many years. We have had the best experience with energy chain. The machine running times are right; complaints are a thing of the past!"

Wolfgang Saehsen, Vice President of SATO Schneidsysteme Anton Hubert e.K. on the co-operation with igus®.

Focus on good cooperation

The length and assignment of the individual energy supply lines are constantly changing. "That's because we don't build standard machines. During assembly, we often have to lengthen or shorten the chains. If we add optional laser pointers at a later stage, for example, they have to be connected with a separate cable. If the corresponding chains are already fully connected, we simply open them and insert the additional cable. Subsequent changes don't cause us any problems," clarifies conductor Reiner Schiffer. "That's why close cooperation is essential before the machines are designed. We don't need off-the-shelf energy supply systems, but special chain widths and lengths that meet our high requirements and prove themselves in tough everyday operation."

Technical sales consultant Ansgar Endries from igus® adds: "We not only offer a wide range of products, but can also provide many customised solutions from stock. And should there ever be a problem, we carry out appropriate tests under real conditions in our own test laboratory. That currently amounts to around 10,000 tests of all kinds per year." In addition to the energy supply systems, various plastic plain bearings and drylin® W-linear technology are also used in the flame-cutting machines. Tests are currently being carried out on the linear guides in particular, which are tailored to the special dirt accumulation during flame cutting in order to further reduce machine downtimes.

"We have been working with the energy chain supplier for many years," concludes Wolfgang Saehsen, Vice President at SATO Schneidmaschinen. "The advice is right, it's the only way we can ensure the required quality - after all, our cutting machines are put to the test in day-to-day operations." The mechanical engineering company always manufactures in Germany. "We also make sure that our suppliers come from German-speaking countries. Given the complexity of our machines, we need contact partners on site who are quickly available in person when needed. And we have had the best experience with energy chain. The machine running times are right; complaints are a thing of the past!"

drylin W profile guide